Plasma sprayed composite coatings were prepared with a mixed powder of AlCuFeB + aluminium. One focus of this study has been the effect of air plasma spraying processing parameters on the characteristics of quasicrystalline composite coating. In this study, Taguchi L9 design of experiments was employed to study the investigated process parameters. Significant effects on the microstructure were observed. For the composite coating (quasicrystal + aluminium) parameters were optimized, considering phase retention and porosity level. Tribological tests were performed with a ball on disk device at room temperature for this composite coating. Results show that quasicrystal phase can be kept in the coating after spraying.